Detailing and polishing pad

ABSTRACT

A polishing pad is adapted for use on a polishing tool. The polishing tool has a support surface for receiving the polishing pad. The polishing pad comprises a polishing layer comprising a fabric polishing surface and a backing layer, the backing layer having an inner and outer surface. The outer surface of the backing layer is adapted to mechanically or adhesively attach in removable fashion to the support surface of the polishing tool. The polishing pad includes a middle layer made from a non-foam, solid thermoplastic polymer in the form of a flexible sheet. The middle layer self-bonds bonded to the polishing layer and the inner surface of the backing layer to form a three-layer polishing pad.

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority to and the benefit of U.S. Provisional Patent Application Ser. No. 61/819,160 that was filed on May 3, 2013, the entirety of which application is hereby incorporated by reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

SEQUENCE LISTING, TABLE OR COMPUTER PROGRAM ON COMPACT DISC

Not applicable.

FIELD OF INVENTION

This invention relates to automotive, marine, aeronautical, household and building maintenance polishing and detail pads.

BACKGROUND OF THE INVENTION

It is known to use manual hand polishing tools or electric rotary or dual action (orbital) polishing tools to polish or detail automobiles, boats, planes, solid surfaces, marble and granite. As used herein, the term “polishing tool” includes both manual and electric polishing tools. When employed to polish or detail a car's paint surface, the prior art polishing tool is outfitted with a polishing and detailing pad. For simplicity, polishing pads and detailing pads are collectively referred to herein as “polishing pads.” Typically, the polishing tool of the prior art has a platen that provides a support surface upon which is adhered an applied outer surface that includes the hook surface features that are compatible with a hook and loop fastening system. The hook surface of the polishing tool is designed to receive and hold a polishing pad through a complementary surface on the polishing pad that includes the loop surface features of the known hook and loop system.

The prior art polishing pad is attachable to the polishing tool by application of the pad's loop surface to the tool's platen with the applied hook surface. By using the book and loop system, the polishing pad is easily detachable from the polishing tool simply by peeling the pad from the platen. Alternatively, the support surface may be a smooth planar surface adapted to receive a polishing pad having a pressure sensitive adhesive applied to the pad's backing. The adhesive is covered by a release layer, such that the release layer can be peeled from the backing to reveal the adhesive layer and the pad adhered to the support surface by application of pressure.

There are several types of polishing pads known in the prior art. Traditionally, polishing pads were made from wool. Wool pads are the oldest pad known in the automotive detailing industry. Wool pads are not used much anymore. When they are used, they are generally used only to remove deeper scratches in an automobile's paint finish. They do so by generating heat to remove the scratches and are often used with electric polishing tools and comparatively heavy polishing compounds. Because of their mechanism of operation, if not used properly wool pads can cause damage like swirls and holograms to a paint's finish.

Another type of polishing pad known in the prior art is the polishing pad with foam polishing surface. This type of polishing pad is known commercially as a “foam polishing pad” or a “foam pad,” and is therefore referred to herein as such. FIG. 1 shows an exemplary prior art foam pad 1. Foam polishing pads are generally considered preferable to wool pads, because of the stated tendency of wool pads to scratch paint. As shown in FIG. 1, the foam polishing pad 1 of the prior art comprises a resilient open cell foam layer 2. The foam pad is soft and flexible so as to allow the pad to follow the curves and contours of an automobile surface. It can work with both rotary and dual action electric polishing tools. Prior art foam polishing pad 1 is a two-layer pad that consists of a layer 2 of relatively thick resilient, open cell foam adhered to the inner surface of a backing layer 3. The backing layer 3 has an outer surface 4 that includes a plurality of loops 5 that allow the pad to releasably attach to a polishing tool. Generally, the foam layer 2 is uniformly a full-thickness open cell foam down to backing layer 3. The polishing surface 6 of the foam layer 2 is usually textured to increase the surface area of the polishing area so as to better hold polishing compounds, sealants and waxes. A variety of foam polishing pads are available, with the foam layer varying in density and softness depending upon the application needed and the type of paint being polished. Some foam pads are designed for heavy “cutting” or compounding and can cut through deep scratches and oxidation in a paint finish. Other foam pads are more applicable to removal of swirls, oxidation and small scratches. Other foam polishing pads are designed to only work on a car's clear coat layer or to simply apply sealant.

A more recently developed polishing pad is the so-called “microfiber pad” with microfiber fabric polishing surface. This prior art polishing pad is depicted in FIG. 2. As shown in FIG. 2, the microfiber pad 10 is a three-layer pad that comprises a polishing layer 11 that employs a microfiber fabric as the pad's polishing surface 12. Microfiber is a soft fabric that is often used by itself as a towel or cloth to wipe down surfaces. The three layers of the prior art pad 10 are as follows: a microfiber polishing layer 11, a middle (“core”) layer 13 for heat distribution and an attachment or backing layer 14. The core layer 13 is a pliable, thick open-cell yellow foam similar to the foam polishing layer 2 of the prior art foam pad 1. The backing layer 14 typically comprises a plurality of soft loops 15 adapted to secure the pad to the support surface of the polishing tool. The support surface has complementary hook surface features.

Often the decision to use a foam polishing pad versus a three-layer microfiber pad depends upon what type of paint is being polished. Foam pads generally work better with “hard” paints and microfiber works better on softer automotive paints found on some manufacturers' models. That said, with the right polishing compounds, the three-layer microfiber polishing pad can be used to cut through many automotive paints to obtain relatively good polishing results.

The three-layer microfiber pad of the prior art does however suffer from a significant deficit. In this respect, heat generated by polishing action causes the foam core to degrade and the pad to delaminate. This is significant as some level of heat is necessary to remove fine scratches, swirls and holograms from automotive paint finish. Because of the degradation and delamination tendencies of current microfiber polishing surface pads, there is a need for an improved polishing pad with a fabric polishing surface.

SUMMARY OF THE INVENTION

According to the present invention there is provided an improved paint finishing pad for finishing the surface of paint that is adapted to be used on a polishing tool that includes a generally planar support surface for receiving the pad. In one embodiment, the present invention polishing pad includes a polishing layer comprising a fabric (preferably microfiber polyester) polishing surface. The polishing pad also includes a backing layer. The backing layer has an inner and outer surface. The outer surface of the backing layer is adapted to mechanically or adhesively attach in removable fashion to the support surface of the polishing tool.

In contrast to the prior art, the present invention polishing pad includes a middle layer made from a non-foam, solid thermoplastic polymer. By non-foam, it is meant that the middle layer is neither an open-cell foam nor a closed-cell foam. This middle layer forms a flexible sheet between the polishing layer and the backing layer. The middle layer is bonded to the polishing layer and the inner surface of the backing layer. In a preferred embodiment, the middle layer is bonded to both the polishing layer and the backing layer solely by virtue of the melding of the thermoplastic polymer into the polishing layer and backing layer.

The fabric polishing surface of the polishing layer of the present invention polishing pad can be any of a microfiber fabric, a cotton fabric, a non-microfiber polyester fabric, a wool fabric or a non-woven fabric. In a preferred embodiment, the polishing surface comprises a microfiber fabric.

In a preferred embodiment, the outer surface of the backing layer comprises a plurality of loops for releasably attaching the polishing pad to a support surface having a plurality of hooks. In an alternate embodiment, the outer surface of the backing layer can comprise a plurality of hooks for releasably attaching the polishing pad to a support surface having a plurality of loops. In another embodiment, the outer surface of the backing layer comprises an adhesive film covered by a release layer for releasably attaching the polishing pad to the support surface of the polishing tool.

The present invention polishing pad thus comprises three layers that utilizes a middle sheet of thermoplastic solid, non-foam polymer (“non-foam thermoplastic polymer”) bonded to the polishing layer and the backing layer. In a preferred embodiment, the non-foam thermoplastic polymer layer is melted into the polishing and backing layers during manufacturing and thus serves as a bonding agent between the polishing layer and the backing layer. The middle layer may even be a non-foam, thermosetting plastic (a/k/a thermoset plastic). In contrast to the prior art, the non-foam thermoplastic polymer sheet layer of the present invention polishing pad is much thinner than the foam core layer of the prior art polishing pad. This thermoplastic polymer layer helps to control the heat in the pad when in use and prevents the pad from breaking down and delaminating during use.

The present invention provides a polishing pad with a fabric polishing layer (preferably polyester microfiber) for finishing and polishing surfaces like automotive paint, paint on a plane, gel coats on boats, solid surfaces, marble and granite. The polishing pad is intended to be machine driven via a rotary or dual action polishing tool. It can be used with hand polishing tools. It can be used with commercially available waxes, sealants and polishing compounds. When compared to the wool, foam and microfiber pads of the prior art, the present invention pad withstands heat, and with little effort, removes fine scratches, swirls and holograms. In addition, with current foam and microfiber pads, consumers must use several different densities of foam to, achieve the finish achievable through the present invention pad. Even then, current foam and microfiber pads cannot remove swirls, holograms or even very fine scratches with the same ease as the present invention pad. The present invention polishing pad provides an environmentally friendly pad that will quickly and efficiently remove swirls, holograms and scratches from surfaces and leave a high gloss finish.

The present invention further includes a method of manufacturing a polishing pad that is adapted for releasable attachment to a polishing tool. The method comprises providing a polishing layer comprising a fabric polishing surface, a backing layer and a meltable and spreadable thermoplastic polymer working material. The thermoplastic polymer working material is melted and then applied to either of the polishing or backing layer. Next, depending upon which layer the thermoplastic polymer working material was applied to, the previously unapplied polishing or backing layer is applied to the applied melted thermoplastic polymer material such that the thermoplastic polymer working material forms a middle layer between the polishing layer and the backing layer. When arranged in this fashion, the polishing layer, the melted thermoplastic polymer layer and the backing layer form a stack. Due to it having been heated and melted, the thermoplastic polymer melds into both the polishing layer and backing layer. The melted thermoplastic in the stack is allowed to recrystallize. After recrystallizing, the thermoplastic polymer forms a middle layer that self-bonds with the polishing layer and backing layer and the stack forms a flexible, three-layer laminated sheet in which the middle layer is a non-foam thermoplastic polymer.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be further described with reference to the accompanying drawings wherein like reference numerals refer to like parts in the several views, and wherein:

FIG. 1 is a perspective view of a prior art foam pad.

FIG. 2 is a perspective view of a prior art microfiber pad.

FIG. 3A is an exploded perspective view of an embodiment of a polishing pad according to the present invention. FIG. 3B is an exploded perspective view, in reverse of that view shown in FIG. 3A, of an embodiment of a polishing pad according to the present invention.

FIG. 4 is front elevation view of the polishing surface of an embodiment of a polishing pad of the present invention.

FIG. 5 is a sectional view taken along line A-A of FIG. 4 showing the layers of an embodiment of a polishing pad according to the present invention.

FIG. 6 is a detail perspective view of an embodiment of the present invention polishing pad in which instead of a backing layer with hook or loop attachment features, the backing layer includes a surface with an adhesive covered by a peelable release layer.

FIG. 7 is a flowchart showing a preferred embodiment manufacturing process for making a preferred embodiment of the present invention polishing pad.

FIGS. 8A-8D depict a preferred embodiment manufacturing process.

DETAILED DESCRIPTION

FIGS. 3A-5 show the present invention polishing pad 20 in a preferred embodiment. These figures depict an improved polishing pad 20 that is adapted to be used on a polishing tool that includes a generally planar support surface for receiving the pad. In one embodiment, polishing pad 20 includes a polishing layer 21 comprising a fabric polishing surface 22. Polishing pad 20 also includes backing layer 23. Backing layer 23 has an inner surface 24 and outer surface 25. Outer surface 25 of backing layer 23 is adapted to mechanically or adhesively attach in removable fashion to the support surface of the polishing tool.

Present invention polishing pad 20 includes a middle layer 26 made from a non-foam, solid thermoplastic polymer. By non-foam, it is meant that the middle layer is neither an open-cell foam nor a closed-cell foam. Middle layer 26 forms a flexible sheet between polishing layer 21 and backing layer 23. Middle layer 26 is bonded to polishing layer 21 and inner surface 24 of backing layer 23. In a preferred embodiment, middle layer 26 is bonded to both the polishing layer 21 and backing layer 23 without adhesives and is bonded to those layers by virtue of the melding of the thermoplastic polymer into polishing layer 21 and backing layer 23.

The present invention further includes a method of manufacturing a polishing pad. FIG. 7 is a flowchart setting out a method 50 by which a preferred embodiment polishing pad can be manufactured. The pad is adapted for releasable attachment to a polishing tool. Method 50 comprises the respective actions 60, 61 and 62 of providing a polishing layer 21 comprising a fabric polishing surface 22, providing a backing layer 23 and providing a meltable and spreadable thermoplastic polymer working material 51. Preferably, thermoplastic polymer working material 51 is provided in pellet form. Actions 60, 61 and 62 may be performed in any order with respect to each other and are not compulsorily sequential in that respect.

In a presently preferred embodiment, non-foam thermoplastic polymer middle layer 26 is made from a commercially available thermoplastic polymer working material 51 comprised of 99-100%—Propene, Polymer with Ethene and additives of 0.1% to less than 1%. The thermoplastic polymer working material 51 is available in pellet form from ThermoTex of Resaca, Ga. under the trade designation or chemical name ThermoTex 8153A. The preferred embodiment thermoplastic polymer working material 51 that is used to form middle layer 26 has a melting point of greater than 120 degrees Celsius.

Next in step 63 the meltable and spreadable thermoplastic polymer working material 51 pellets are heated to a temperature greater than 120 degrees C. and melted to create unapplied melted thermoplastic polymer 53. In step 64, melted thermoplastic polymer 53 is applied to either of polishing layer 21 or backing layer 23 to create melted thermoplastic polymer layer 52. Next in step 65, depending upon which layer the melted thermoplastic polymer layer 52 was applied to, the previously unapplied polishing layer 21 or backing layer 23 is applied to the applied melted thermoplastic polymer layer 52. Upon application of the previously unapplied layer to layer 52, layer 52 becomes a middle layer of melted thermoplastic polymer between polishing layer 21 and backing layer 23. When arranged in this fashion, polishing layer 21, the melted thermoplastic polymer middle layer 52 and backing layer 23 form a stack 55. Due to having been heated and melted, thermoplastic polymer layer 52 in stack 55 melds into both polishing layer 21 and backing layer 23.

In step 66, stack 55 is cooled or allowed to cool (both actions collectively referred to as “cooling the stack” or “cool the stack”). In a preferred method, stack 55 is run over a cooling roller. In step 67, thermoplastic layer 52 in stack 55 with the melted thermoplastic polymer is allowed to recrystallize. After a period of time in which recrystallizing is complete, the middle layer 52 recrystallizes to form final thin non-foam thermoplastic polymer middle layer 26. By virtue of the melting and melding process, layer 26 is bonded to polishing layer 21 and backing layer 23 without use of any other adhesives between the layers. Recrystallized stack 55 is a flexible, three-layer laminated sheet in which middle layer 26 is a non-foam thermoplastic polymer. Because middle layer 26 is a non-foam thermoplastic polymer it distributes heat efficiently and does not degrade during use like polishing pads with foam cores. The present invention polishing pad can be made with a thermosetting plastic as the non-foam middle layer using the techniques described herein.

A real-world example of the present invention method 50 is shown in FIGS. 8A-8D and will now be discussed. As shown in FIG. 8A, present invention pad 20 can be made on an automated line 70 in which backing layer 23 is fed through layering machine 71 to an area where the granular and meltable thermoplastic polymer material 51 is melted (creating melted thermoplastic polymer 53) via applied heat 72. Melted thermoplastic 53 is then applied to backing layer 23. Once applied to backing layer 23, the melted thermoplastic polymer becomes melted thermoplastic layer 52. Next, as is also shown in FIG. 8A, polishing layer 21 is applied over the top of the applied and melted thermoplastic polymer layer 52. A three-layer stack 55 (FIG. 8B) is formed that comprises melted middle layer 52 situated between polishing layer 21 and backing layer 23. Due to its melted state, middle layer 52 melds it into polishing layer 21 and backing layer 23. As shown in FIG. 8C, stack 55 is cooled over a cooling roller and melted middle layer 52 cools (heat 72 removed). During cooling, middle layer 52 recrystallizes. As shown in FIG. 8D, as a result of heating and recrystallizing, middle layer 52 forms into non-foam thermoplastic polymer sheet layer 26. By virtue of the flow of melted layer 52 during the stack-forming process, the resulting recrystallized middle layer 26 is now between and melded into polishing layer 21 and backing layer 23. This is shown in FIG. 8D wherein the top and bottom surfaces of middle layer 26, respectively adjacent to polishing layer 21 and backing layer 23, are shown as jagged instead of smooth to represent melding of thermoplastic material. The resulting polishing pad is a flexible, three-layer laminated sheet in which middle layer 26 is a thin, non-foam thermoplastic polymer. The width of the material and the process speeds can vary. Once the layering process is complete, the flexible, laminated sheet is rolled. The rolls are die cut into specific sizes per customers' request. The finished polishing pads are typically round, but can be cut in any shape.

Critically, middle layer 26 is a non-foam thermoplastic polymer sheet bonded to polishing layer 21 and backing layer 23. In a preferred embodiment, the non-foam thermoplastic polymer layer 26 is melted into polishing layer 21 and backing layer 23 during manufacturing and thus serves as a bonding agent between polishing layer 21 and backing layer 23. In an alternative embodiment, a polishing pad of the present invention structure could include a pre-formed middle layer 26 that is adhered to layers 21 and 23 through use of adhesives.

In contrast to prior art automotive polishing pads, the present invention polishing pad is much thinner. Current foam and microfiber pads are on the order of an inch or more in thickness. The present invention pad is on the order of 4.175-7.9375 millimeters ( 3/16- 5/16 inches) thick depending upon the polishing fabric. In addition, in contrast to the prior art, middle layer 26 of the present invention polishing pad is much thinner than the foam core layer 13 of the prior art polishing pad 10. In a preferred embodiment, middle layer 26 has a thickness of approximately 1.5 millimeters. Even so, non-foam thermoplastic polymer middle layer 26 helps to control the heat in the pad when in use and prevents pad 20 from breaking down and delaminating during use. These thickness differences in pad 20 and middle layer 26 mean that the present invention pad takes up less space than either a foam pad or current microfiber pad of the same diameter or polishing area. This, in turn means, that the present invention polishing pad will take up less shelf space in stores and less shipping volume per count than known polishing pads.

The present invention provides a polishing pad 20 with a polishing layer 21 with fabric polishing surface 22. Fabric polishing surface 22 of polishing layer 21 of polishing pad 20 can be or comprise any of a microfiber fabric, a cotton fabric, a non-microfiber polyester fabric, a wool fabric or a non-woven fabric. In a preferred embodiment, polishing surface 22 is or comprises a microfiber fabric. Polishing pad 20 is intended to be machine driven via a rotary or dual action polishing tool. It can, however, be used with hand polishing tools. It can be used with commercially available waxes, sealants and polishing compounds. As noted, as compared to the wool, foam and microfiber pads of the prior art, the present invention pad withstands heat generated during polishing and requires less effort, removes fine scratches, swirls and holograms.

In a preferred embodiment, outer surface 25 of backing layer 23 comprises a plurality of loops 27 for releasably attaching polishing pad 20 to a support surface having a plurality of hooks (not shown). In an alternate embodiment, the outer surface of the backing layer can comprise a plurality of hooks for releasably attaching polishing pad 20 to a support surface having a plurality of loops. In another embodiment shown in FIG. 6, outer surface 25 of backing layer 23 comprises a pressure sensitive adhesive film 28 covered by a release layer 29 for releasably attaching polishing pad 20 to the support surface of the polishing tool.

The present invention has now been described with reference to preferred embodiments and variations thereof. It will be apparent to those skilled in the art that many changes can be made in the embodiment described without departing from the scope of the present invention. Thus the scope of the present invention should not be limited to the structure described in this application, but only by structures described by the language of the claims and the equivalents of those structures. 

What is claimed is:
 1. A polishing pad for use on a polishing tool, the polishing tool having a support surface for receiving the pad, the polishing pad comprising: a polishing layer comprising a fabric polishing surface; a backing layer, the backing layer having an inner surface and outer surface; the outer surface of the backing layer adapted to mechanically or adhesively attach in removable fashion to the support surface of the polishing tool; and a non-foam, solid thermoplastic polymer middle layer in the form of a flexible sheet, the middle layer bonded to the polishing layer and the inner surface of the backing layer.
 2. The polishing pad of claim 1 wherein the middle layer is bonded to both the polishing layer and the backing layer by melding of the thermoplastic polymer into the polishing layer and backing layer.
 3. The polishing pad of claim 1 wherein the fabric polishing surface of the polishing layer is or comprises a microfiber fabric, a cotton fabric, a non-microfiber polyester fabric, a wool fabric or a non-woven fabric.
 4. The polishing pad of claim 1 wherein the outer surface of the backing layer comprises a plurality of loops for releasably attaching the polishing pad to a support surface having a plurality of hooks.
 5. The polishing pad of claim 1 wherein the outer surface of the backing layer comprises a plurality of hooks for releasably attaching the polishing pad to a support surface having a plurality of loops.
 6. The polishing pad of claim 1 wherein the outer surface of the backing layer comprises an adhesive film covered by a release layer for releasably attaching the polishing pad to the support surface of the polishing tool.
 7. A method of manufacturing a polishing pad adapted for releasable attachment to a polishing tool, the method comprising: providing a polishing layer comprising a fabric polishing surface, a backing layer and a thermoplastic polymer working material; melting the thermoplastic polymer working material; applying the melted thermoplastic polymer working material to either of the polishing or backing layer; applying the previously unapplied polishing or backing layer to the melted and applied thermoplastic polymer working material such that the melted thermoplastic polymer working material forms a middle layer of melted thermoplastic polymer between the polishing layer and the backing layer and the polishing layer, the melted thermoplastic polymer middle layer and the backing layer form a stack; and cooling the stack such that the melted thermoplastic polymer of the middle layer recrystallizes and that upon the melted thermoplastic polymer recrystallizing: the melted thermoplastic polymer forms into a solid, flexible, non-foam thermoplastic polymer middle layer bonded to the polishing layer and backing layer; and the stack is a flexible, three-layer laminated sheet.
 9. A polishing pad for use on a polishing tool, the polishing tool having a support surface for receiving the pad, the polishing pad comprising: a polishing layer comprising a fabric polishing surface; a backing layer, the backing layer having an inner surface and outer surface; the outer surface of the backing layer adapted to mechanically or adhesively attach in removable fashion to the support surface of the polishing tool; and a non-foam, solid thermoset polymer middle layer in the form of a flexible sheet, the middle layer bonded to the polishing layer and the inner surface of the backing layer. 